US12215427B2ActiveUtilityA1

Erosion and CMAS resistant coating for protecting EBC and CMC layers and thermal spray coating method

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Assignee: OERLIKON METCO US INCPriority: Dec 19, 2017Filed: Dec 18, 2018Granted: Feb 4, 2025
Est. expiryDec 19, 2037(~11.4 yrs left)· nominal 20-yr term from priority
Inventors:Dianying ChenChris Dambra
C23C 14/083F01D 5/288C23C 28/3455C23C 28/321C23C 4/134C23C 4/11Y02T50/60C04B 41/52C04B 41/009C04B 41/89C23C 28/042
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Cited by
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References
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Claims

Abstract

An erosion and CMAS resistant coating arranged on an EBC coated substrate includes at least one porous vertically cracked (PVC) coating layer providing CTE mitigation and being disposed over the EBC coated substrate. At least one dense vertically cracked (DVC) erosion and CMAS resistant coating layer is deposited over the at least one PVC coating layer.

Claims

exact text as granted — not AI-modified
What is claimed: 
     
       1. An erosion and calcium-magnesium-aluminum-silicate (CMAS) resistant coating arranged on an environmental barrier coating (EBC) coated substrate, in which at least one bond coating layer is disposed between the EBC and the substrate, the erosion and CMAS resistant coating comprising:
 at least one porous vertically cracked (PVC) coating layer providing CTE mitigation and being disposed over the EBC coated substrate, the substrate comprising a ceramic matrix composite (CMC); and 
 at least one dense vertically cracked (DVC) erosion and CMAS resistant coating layer deposited over the at least one PVC coating layer, 
 wherein a porosity of the at least one DVC erosion and CMAS resistant coating is 0% to 5%, and 
 wherein a porosity of the at least one PVC coating layer is 5% to 25%. 
 
     
     
       2. The coating of  claim 1 , wherein the at least one DVC layer is a top layer. 
     
     
       3. The coating of  claim 1 , wherein the at least one bond coating layer disposed between the EBC and the substrate comprises at least one of Si, Si-HfO 2  or S-rare earth (Re). 
     
     
       4. The coating of  claim 1 , wherein the substrate is an Si-based CMC substrate. 
     
     
       5. The coating of  claim 1 , wherein the at least one DVC erosion and CMAS resistant coating layer comprises Re stabilized ZrO 2  mixed with rare earth oxide or Re stabilized HfO 2  mixed with rare earth oxide. 
     
     
       6. The coating of  claim 1 , wherein the at least one DVC erosion and CMAS resistant coating layer comprises Re stabilized ZrO 2  mixed with rare earth silicate or Re stabilized HfO 2  mixed with rare earth silicate. 
     
     
       7. The coating of  claim 1 , wherein the at least one DVC erosion and CMAS resistant coating layer comprises Re stabilized ZrO 2  mixed with rare earth aluminate or Re stabilized HfO 2  mixed with rare earth aluminate. 
     
     
       8. The coating of  claim 1 , wherein the at least one DVC erosion and CMAS resistant coating layer comprises Re stabilized ZrO 2  mixed with rare earth aluminate or silicate or Re stabilized HfO 2  mixed with rare earth aluminate or silicate. 
     
     
       9. The coating of  claim 1 , wherein the at least one DVC erosion and CMAS resistant coating layer comprises Re stabilized ZrO 2  mixed with alkaline oxide or Re stabilized HfO 2  mixed with alkaline oxide. 
     
     
       10. The coating of  claim 1 , wherein the at least one DVC erosion and CMAS resistant coating layer comprises Re stabilized ZrO 2  mixed with gadolinium zirconate or Re stabilized HfO 2  mixed with gadolinium zirconate. 
     
     
       11. The coating of  claim 1 , wherein the at least one DVC erosion and CMAS resistant coating layer comprises a mixture of two or more of:
 Re stabilized ZrO 2  mixed with rare earth oxide; 
 Re stabilized HfO 2  mixed with rare earth oxide; 
 Re stabilized ZrO 2  mixed with rare earth silicate; 
 Re stabilized HfO 2  mixed with rare earth silicate; 
 Re stabilized ZrO 2  mixed with rare earth aluminate; 
 Re stabilized HfO 2  mixed with rare earth aluminate; 
 Re stabilized ZrO 2  mixed with rare earth aluminate or silicate; 
 Re stabilized HfO 2  mixed with rare earth aluminate or silicate; 
 Re stabilized ZrO 2  mixed with alkaline oxide; 
 Re stabilized HfO 2  mixed with alkaline oxide; 
 Re stabilized ZrO 2  mixed with gadolinium zirconate; or 
 Re stabilized HfO 2  mixed with gadolinium zirconate. 
 
     
     
       12. The coating of  claim 1 , wherein the at least one DVC erosion and CMAS resistant coating layer comprises full thickness vertical cracks. 
     
     
       13. The coating of  claim 1 , wherein the at least one PVC coating layer comprises full thickness vertical cracks. 
     
     
       14. The coating of  claim 1 , wherein:
 the substrate is a CMC substrate; 
 the EBC coated substrate comprises an EBC coating layer bonded to the substrate; 
 the at least one PVC coating layer is a PVC ceramic coating layer directly deposited on the EBC coating layer; and 
 the at least one DVC erosion and CMAS resistant coating layer is deposited directly on the PVC coating layer. 
 
     
     
       15. A method of plasma spraying the erosion and CMAS resistant coating of  claim 1  on the EBC coated substrate, in which the at least one bond coating layer is disposed between the EBC and the substrate, the method comprising:
 depositing the at least one PVC coating layer as a PVC thermal barrier coating layer providing CTE mitigation onto the EBC coated substrate; and 
 depositing the at least one DVC erosion and CMAS resistant coating material over the at least one PVC thermal barrier coating layer. 
 
     
     
       16. The method of  claim 15 , wherein the at least one bond coating layer arranged between an EBC layer and the substrate comprises at least one of Si, Si—HfO 2  or S-Re. 
     
     
       17. The method of  claim 16 , wherein the plasma spraying comprises one of:
 atmospheric plasma spraying (APS); 
 plasma spray-physical vapor deposition (PS-PVD); or 
 suspension plasma spray (SPS). 
 
     
     
       18. An erosion and calcium-magnesium-aluminum-silicate (CMAS) resistant coating arranged on an environmental barrier coating (EBC) coated substrate, in which at least one bond coating layer is disposed between the EBC and the substrate, the erosion and CMAS resistant coating comprising:
 at least one porous vertically cracked (PVC) thermal barrier coating layer providing coefficient of thermal expansion (CTE) mitigation and being disposed over the EBC coated substrate, the substrate comprising a ceramic matrix composite (CMC); and 
 a top layer of dense vertically cracked (DVC) erosion and CMAS resistant coating material deposited over the at least one PVC thermal barrier coating layer, 
 wherein a porosity of the at least one DVC erosion and CMAS resistant coating material is 0% to 5%, and 
 wherein a porosity of the at least one PVC thermal barrier coating layer is 5% to 25%. 
 
     
     
       19. The coating of  claim 18 , wherein the at least one bond coating layer disposed between the EBC and the substrate comprises at least one of Si, Si—HfO 2  or S-Re. 
     
     
       20. The coating of  claim 18 , wherein the substrate is an Si-based CMC substrate. 
     
     
       21. The coating of  claim 18 , wherein the at least one DVC erosion and CMAS resistant coating layer comprises Re stabilized ZrO 2  mixed with rare earth oxide or Re stabilized HfO 2  mixed with rare earth oxide. 
     
     
       22. The coating of  claim 18 , wherein the at least one DVC erosion and CMAS resistant coating layer comprises Re stabilized ZrO 2  mixed with rare earth silicate or Re stabilized HfO 2  mixed with rare earth silicate. 
     
     
       23. The coating of  claim 18 , wherein the at least one DVC erosion and CMAS resistant coating layer comprises Re stabilized ZrO 2  mixed with rare earth aluminate or Re stabilized HfO 2  mixed with rare earth aluminate. 
     
     
       24. The coating of  claim 18 , wherein the at least one DVC erosion and CMAS resistant coating layer comprises Re stabilized ZrO 2  mixed with rare earth aluminate or silicate or Re stabilized HfO 2  mixed with rare earth aluminate or silicate. 
     
     
       25. The coating of  claim 18 , wherein the at least one DVC erosion and CMAS resistant coating layer comprises Re stabilized ZrO 2  mixed with alkaline oxide or Re stabilized vHfO 2  mixed with alkaline oxide. 
     
     
       26. The coating of  claim 18 , wherein the at least one DVC erosion and CMAS resistant coating layer comprises Re stabilized ZrO 2  mixed with gadolinium zirconate or Re stabilized HfO 2  mixed with gadolinium zirconate. 
     
     
       27. The coating of  claim 18 , wherein the at least one DVC erosion and CMAS resistant coating layer comprises a mixture of two or more of:
 Re stabilized ZrO 2  mixed with rare earth oxide; 
 Re stabilized HfO 2  mixed with rare earth oxide; 
 Re stabilized ZrO 2  mixed with rare earth silicate; 
 Re stabilized HfO 2  mixed with rare earth silicate; 
 Re stabilized ZrO 2  mixed with rare earth aluminate; 
 Re stabilized HfO 2  mixed with rare earth aluminate; 
 Re stabilized ZrO 2  mixed with rare earth aluminate or silicate; 
 Re stabilized HfO 2  mixed with rare earth aluminate or silicate; 
 Re stabilized ZrO 2  mixed with alkaline oxide; 
 Re stabilized HfO 2  mixed with alkaline oxide; 
 Re stabilized ZrO 2  mixed with gadolinium zirconate; or 
 Re stabilized HfO 2  mixed with gadolinium zirconate. 
 
     
     
       28. The coating of  claim 18 , wherein the top layer of DVC erosion and CMAS resistant coating layer comprises full thickness vertical cracks. 
     
     
       29. The coating of  claim 18 , wherein the at least one PVC coating layer comprises full thickness vertical cracks.

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